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Industrial Manufacturing & Fabrication
The steel industry is the largest user of oxygen. Oxygen is also used in the manufacture of other metals, such as copper and lead.

Applications Using Oxygen:

  • Steel Making
  • Lead and Copper Smelting
  • Oxygen Lancing
  • Oxy-acetylene cutting, welding and brazing
  • Oxygen-Enriched Combustion
  • Oxy-Fuel Burners
    • Electric Arc Furnaces (EAF’s) for steel scrap melting
    • Cupola furnaces for cast iron production
    • Rotary furnaces for copper and its alloys melting
    • Rotary and reverberatory furnace for aluminum production
    • Rotary and blast furnaces for lead manufacture
    • Crucible furnaces for gold and silver scrap processing

Oxygen is used in the production of both ferrous and nonferrous metals for two main purposes:

  • Enhanced Productivity
  • Reduced Fuel Consumption

By replacing some or all of the combustion air in the burners that are used in melting furnaces, flame temperature and heat transfer are increased while there is a significant reduction in exhaust gas volume and content (e.g. NOx, VOC’s).  The combustion reaction of methane (natural gas) is shown below:

CH4 + 2O2 + 8N2 CO2 + 2H2O + 8N2

The nitrogen in the air does not enter into the combustion reaction and actually contributes to the energy losses due to the hot exhaust gases leaving the furnace by as much as 40-50%. By adding oxygen to the combustion air, the concentration of nitrogen is significantly reduced depending on the percentage of oxygen enrichment.  The major benefits of oxygen combustion are:

  • Productivity improvement (10-25%)
  • Exhaust gas volume reduction (25-60%)
  • Higher melting rates (15-30%)
  • NOx and VOC reductions in exhaust gas
  • Fuel savings (10-40%)

In general, there are three types of oxygen combustion process:

Burners Banner2

Oxy-fuel burners have been developed for a wide range of metal production furnaces, including:

  • Electric Arc Furnaces (EAF’s) for steel scrap melting
  • Rotary and reverberatory furnace for aluminum production
  • Cupola furnaces for cast iron production
  • Rotary and blast furnaces for lead manufacture
  • Rotary furnaces for copper and its alloys melting
  • Crucible furnaces for gold and silver scrap processing

It is necessary to insure the proper supply of oxygen to the combustion system. In terms of oxygen purity, it has been determined that 90% and higher will provide the maximum benefits of productivity improvement and fuel savings. In that regard, PCI’s full line of DOCS oxygen production units are ideally suited for these combustion applications.

The substitution of conventional air-fuel burners with oxy-fuel burners positively affects furnace operation by:

  • Reduced melting costs
  • Higher operating flexibility
  • Reduced melting times
  • Higher slag/metal separation
  • Decreased off-gas volume
  • Reduced metal oxidation and loss

It is necessary to insure the proper supply of oxygen to the combustion system. In terms of oxygen purity, it has been determined that 90% and higher will provide the maximum benefits of productivity improvement and fuel savings. In that regard, PCI’s full line of DOCS oxygen production units are ideally suited for these combustion applications.

The substitution of conventional air-fuel burners with oxy-fuel burners positively affects furnace operation by:

  • Reduced melting costs
  • Higher operating flexibility
  • Reduced melting times
  • Higher slag/metal separation
  • Decreased off-gas volume
  • Reduced metal oxidation and loss

OXYGEN GENERATOR MODELS

MODEL DESCRIPTION FLOW PRESSURE PURITY
DOCS 80 220V / 3-Phase / 60Hz or 208V / 3-Phase / 50Hz 80 lpm 20-100 psig 93% +/- 3%
DOCS 200 460V / 3-Phase / 60Hz or 380V / 3-Phase / 50Hz 200 lpm 20-100 psig 93% +/- 3%
DOCS 500 460V / 3-Phase / 60Hz or 380V / 3-Phase / 50Hz 500 lpm 20-100 psig 93% +/- 3%
DOCS 1500 460V / 3-Phase / 60Hz or 380V / 3-Phase / 50Hz 1500 lpm 3-12 psig 93% +/- 3%
DOCS 1500 Booster 460V / 3-Phase / 60Hz or 380V / 3-Phase / 50Hz 1500 lpm 20-100 psig 93% +/- 3%
DOCS 5000 460V / 3-Phase / 60Hz or 380V / 3-Phase / 50Hz 5000 lpm 3-12 psig 93% +/- 3%
DOCS 5000 Booster 460V / 3-Phase / 60Hz or 380V / 3-Phase / 50Hz 5000 lpm 20-100 psig 93% +/- 3%